Continuous forming of transverse stiffening ribs on strip material

ABSTRACT

Method of and machine for forming transverse ribs in metal strip wherein the strip is fed through a pair of back tension rolls, over a die roll having a series of elliptical shaped recesses extending transversely of and around the periphery of the die roll, a series of rotary punch rolls engaging the strip on the die roll and deforming the strip into the recesses, a forward tension roll engaging the deformed strip on the die roll and controlling the feed out of strip from the machine, the back tension rolls and the forward tension roll being driven by gearing providing a speed differential between these rolls and thus indicating tension in the strip as it passes over the die roll.

[ July 4, 1972 United States Patent Clem pson CONTINUOUS FORMING OFTRANSVERSE STIFFENING RIBS ON STRIP MATERIAL [72] Inventor: PhilipGeorge Clempson, Donvale, Victoria, Australia |57| ABSTRACT Method ofand machine for forming transverse ribs in metal strip wherein the stripis fed through a pair of back tension rolls, over a die roll having aseries of elliptical shaped recesses extending transversely of andaround the periphery of the die roll, a series of rotary punch rollsengaging the strip on the die roll and deforming the strip into therecesses, a forward tension roll engaging the deformed strip on the dieroll and con trolling the feed out of strip from the machine, the backtension rolls and the forward tension roll being driven by gearingproviding a speed differential between these rolls and thus indicatingtension in the strip as it passes over the die roll.

0 n 7 2 Y m w mm a 7 H i n ""4 u ""9 N I wi US "I .n mu m mm7 .w 0 "mm a7 H m mm 9 .m um MA 9 H m t 2 7 "H" WM 5 W rm m s m h Bl. J 6 n N I m iw 0 WHQM n U M m d w .Cd m M P SMM A F A UIF .l ii iii 1 2 I 2I8 7 2 2555 12 Claims, 3 Drawing Figures {56] References Cited UNITED STATESPATENTS 3,394,573 7/1968Bodnari.i.................................72/I96 SHEET 2!]? 2PATENTFUJUL 4 m2 CONTINUOUS FORMING OF TRANSVERSE S'IIFFENING RIBS ONSTRIP MATERIAL BACKGROUND OF INVENTION This invention relates to amethod and apparatus for forming transverse stifl'ening ribs on stripmaterial, in particular on coils or lengths of metal strip, suitable forsubsequent fonning into decking, tiling, walling, cladding, flooring,concrete framework and other building structure forms.

Structural members or panels of this general type as heretofore usedhave consisted of a sheet or strip of material provided with upstandingribs or flanges along its longitudinal edges to enable adjacent panelsto be joined along said edges and to stiffen and increase the loadbearing capacity of the panels. Further longitudinally extending ribs orflanges have been provided in the pan of the panel for additionalstiffening purposes.

In use these prior known panels have a number of disadvantages. Onemajor disadvantage is that the ribs are mainly effective only asstiffeners and increase the load bearing capacity of the panel ormultiple panel structure only in the region or near the vicinity of theribs. This has of consequence required the basic design of the knownpanels to be limited to the provision of a comparatively short pan widthbetween the jointed or interlocking edge ribs or the provision ofintermediate longitudinal ribs between the edge ribs of each panel,resulting in a number of pans of narrow width in each panel, with anincreased use of material.

The provision of transverse ribs in structural members or panels of theabove general type in place of the longitudinal stiffening ribs resultsin a load bearing structure wherein all loading over the panel istransferred to the edge ribs thereby allowing greater span between theribs with considerable saving in material, even if the edge ribs aremade heavier than known ribs, and results in a stronger, more economicaland efficient structure with the advantage of the pan portion beingplate-like in performance.

In order to economically produce such transversely-ribbed structuralmembers or panels, the transverse rib forming operation of necessityshould be carried out continuously on a length or coil of the metalstrip. Press techniques are known employing pressure plates to obviateweb deformation but the use of pressure plate equipment and presstechniques to produce structurally suitable transverse ribs at closecenters continuously at speeds up to one hundred and fifty feet perminute has been found to be impractical.

In order to provide the type of web restraint available with pressureplates, but on a continuous forming basis and at the order of speedquoted above, applicant has devised a stretchforrning technique in atransverse rib forming machine through which strip could be passed atsuitable production speeds, and at the same time inducing tension in theweb up to and beyond, if necessary, the yield point of the metal, thetension being considered as a continuously available alternative for thefunction provided by pressure plates.

According to the present invention there is provided a method ofcontinuously forming transverse ribs in metal strip comprising the stepsof feeding the strip through a transverse rib forming machine, applyingtension to the strip over a die roll in the machine, and rotary punchforming ribs in the strip at a region of said applied tension.

The tension may be induced in the strip by applying a controlled speeddifferential between the input and output feed rolls of the machine, andthe forming operation may be performed by a plurality of rotary punchrolls arranged around a peripheral section of the die roll over whichthe strip passes.

According to a further aspect of the invention there is provided atransverse rib forming machine for continuously forming transverse ribsin a metal strip, comprising strip feed-in rolls, a die roll arrangedparallel to and spaced from said feedin rolls and having a series ofrecesses arranged around its peripheral surface, at least one rotarypunch roll arranged so as to be in forming engagement with the strippassing over the die roll and a take-ofl roll arranged so as to be infrictional engagement with the formed strip and the die roll, saidfeed-in rolls and the take-ofi roll having a drive arrangement providinga speed differential therebetween so as to induce tension in the stripas it passes over the die roll.

The feed-in rolls and the take-off roll may each be provided with anelastomer surface to prevent undesirable slippage of the strip andconsequential loss of tension over the die roll.

A plurality of rotary punch rolls may be provided around a section ofthe periphery of the die roll so as to facilitate formation of the ribsby gradual deformation.

In order that the invention and its manner of performance may be morefully described, reference will now be made to embodiment of theinvention as illustrated in the accompanying drawings in which:

FIG. 1 is a plan view of the apparatus of the invention.

FIG. 2 is a part sectional side view taken along line 22 of FIG. I, and

FIG. 3 is a sectional side view taken along the line 3-3 of FIG. 1.

Referring to the drawings, the apparatus includes roll supporting sideframes 5 connected by star bars or the like. Mounted between frames 5for rotation therein are nip roll 6 and back tension roll 7, die roll 8,rotary punch rolls 9, l0 and 1 l and forward tension roll 12.

Die roll 8 is driven by a variable speed electric motor 13 throughreduction gearing 14. Pinion gear 15 on the die roll drive shaft mesheswith gear 16 of back tension roll 7 and gear 17 of forward tension roll12. The drive through to back tension roll 7 is by way of a slippingclutch 18, and the gearing is such that back tension roll 7 tends to bedriven so that its surface speed is slower than the surface speed of dieroll 8.

Rotary punch rolls 9, 10 and 11 are driven through pinions 19, 20 and 21and pinion 22 on the die roll shaft.

Nip roll 6 and back tension roll 7 are each provided with an elastomersurface 23, 24 and roll 6 is mounted for movement towards and away fromroll 7 by fluid pressure rams 25 mounted on side frames 5.

Die roll 8 is provided on its peripheral surface with diamond orelliptical shaped recesses 26 having their greatest depth at the centerand reducing in depth and width towards the sides of the die roll androtary punch rolls 9, 10 and I I are provided with projecting punches 27spaced around the punch rolls so as to mate with the die roll recesses26 during operation of the apparatus. Punch rolls 9, I0 and 11 aremounted as an assembly on sliding blocks 28 for adjustment towards andaway from die roll 8 by means of adjusting screw handles 29 or ifdesired, fluid pressure ram means.

Forward tension roll 12 is also provided with an elastomer surface 30and is adjustable towards and away from die roll 8 on sliding bearingblocks 31 through adjusting screws 32. Fluid pressure rams may also besubstituted for screws 32, if desired.

Rotary punch rolls 9, 10 and 11 may be provided with back up rolls (notshown) acting in known manner to counteract any tendency of the punchrolls to deflect under high pressure.

In operation, strip 33 is fed between rolls 6 and 7, around roll 7 andon to die roll 8, past rotary punch rolls 9, l0 and 11 and out betweendie roll 8 and forward tension roll 12.

With the strip passed through the apparatus, roll 6 is engaged with roll7 through fluid pressure rams 25 and forward tension roll 12 is engagedagainst die roll 8. Roll 12 engages die roll 8 at a relatively highpressure to induce sufficient friction on the strip between these rollsso as to obviate any slip back of the strip towards the punch rolls.

By reason of the speed differential set up through the apparatus andslipping clutch I8, tension is built up in the strip from the nipbetween rolls 6 and 7 to the area of transfer of the strip to die roll 8where the strip is laid on the die roll under the required degree oftension and is held under that degree of tension until it passes throughthe nip between forward tension roll 12 and die roll 8.

As the strip passes btlween rotary punch rolls 9, 10 and 11 and die roll8, the rotary punch rolls form the ribs to depth.

Further nip rolls may be located so as to engage against the strip onthe die roll between the rotary punch rolls and either or both the backtension and forward tension rolls so as to induce additional frictionbetween the formed strip and the die roll.

Although only three rotary punch rolls are illustrated in the drawings,four or more punch rolls may be employed to facilitate accurate forming.

l claim:

1. A forming machine for continuously forming transverse ribs in a metalstrip, comprising strip back tension rolls, a die roll arranged parallelto and spaced from said back tension rolls and having a series ofrecesses arranged around its peripheral surface, at least one rotarypunch roll arranged so as to be in forming engagement with the strippassing over the die roll, and a forward tension roll arranged so as tobe in frictional engagement with the formed strip and the die roll, saidback tension rolls and the forward tension roll having a drivearrangement providing a speed difl'erential therebetween so as to inducetension in the strip as it passes over the die roll.

2' A machine according to claim 1 wherein the peripheral surfaces of theback tension rolls and the forward tension roll are of elastomermaterial.

3. A machine according to claim 1 wherein a plurality of rotary punchrolls are provided around a section of the periphery of the die roll.

4. A machine according to claim 3 wherein the rotary punch rolls areeach provided with at least one punch member, the dimensions of thepunches varying between the first punch roll and the last punch roll soas to form the ribs by gradual deformation.

5. A machine according to claim 4 wherein the punch rolls are providedwith back-up rolls so as to counteract any tendency of the punch rollsto deflect under forming pressure.

6 A machine according to claim 1 wherein the drive arrangement comprisesa variable speed motor driving the die roll which is in drivingengagement with the back tension rolls,

forward tension roll and rotary punch roll or rolls by means of gearpinions, said drive from the die roll to the back tension rolls alsoincorporating a slipping clutch.

7. A machine according to claim 1 wherein the back tension rolls areadjustably mounted with respect to each other and the forward tensionroll and rotary punch roll or rolls are adjustably mounted with respectto the die roll.

8. A machine according to claim 1 wherein the die roll recesses are ofelliptical or diamond shape having their greatest depth at the centerand reducing in depth and width towards the sides of the die roll.

9. A machine according to claim 7 and including an additional nip rolllocated between the rotary punch roll or rolls and the forward tensionroll so as to engage against the formed strip on the die roll and induceadditional friction between the strip and the die roll.

10. A machine according to claim 7 and including an additional nip rolllocated between the rotary punch roll or rolls and the back tension rollso as to engage against the formed strip on the die roll and induceadditional friction between the strip and the die roll.

11. A machine according to claim 7, including additional nip rollslocated between the rotary punch roll or rolls and the forward and backtension rolls so as to engage against the formed strip on the die rolland induce additional friction between the strip and the die roll.

12. A method of continuously forming transverse ribs in metal stripcomprising the steps of feeding the strip through a transverse ribforming machine, applying tension to the strip over a die roll in themachine by applying a controlled speed differential between input andoutput rolls of the machine, and rotary punch forming ribs in the stripat a region of said applied tension by a plurality of punch rollsarranged in forming engagement with and around a peripheral section ofthe die roll and synchronized for rotation with said die roll.

l i l

1. A forming machine for continuously forming transverse ribs in a metalstrip, comprising strip back tension rolls, a die roll arranged parallelto and spaced from said back tension rolls and having a series ofrecesses arranged around its peripheral surface, at least one rotarypunch roll arranged so as to be in forming engagement with the strippassing over the die roll, and a forward tension roll arranged so as tobe in frictional engagement with the formed strip and the die roll, saidback tension rolls and the forward tension roll having a drivearrangement providing a speed differential therebetween so as to inducetension in the strip as it passes over the die roll.
 2. A machineaccording to claim 1 wherein the peripheral surfaces of the back tensionrolls and the forward tension roll are of elastomer material.
 3. Amachine according to claim 1 wherein a plurality of rotary punch rollsare provided around a section of the periphery of the die roll.
 4. Amachine according to claim 3 wherein the rotary punch rolls are eachprovided with at least one punch member, the dimensions of the punchesvarying between the first punch roll and the last punch roll so as toform the ribs by gradual deformation.
 5. A machine according to claim 4wherein the punch rolls are provided with back-up rolls so as tocounteract any tendency of the punch rolls to deflect under formingpressure.
 6. A machine according to claim 1 wherein the drivearrangement comprises a variable speed motor driving the die roll whichis in driving engagement with the back tension rolls, forward tensionroll and rotary punch roll or rolls by means of gear pinions, said drivefrom the die roll to the back tension rolls also incorporating aslipping clutch.
 7. A machine according to claim 1 wherein the backtension rolls are adjustably mounted with respect to each other and theforward tension roll and rotary punch roll or rolls are adjustablymounted with respect to the die roll.
 8. A machine according to claim 1wherein the die roll recesses are of elliptical or diamond shape havingtheir greatest depth at the center and reducing in depth and widthtowards the sides of the die roll.
 9. A machine according to claim 7 andincluding an additional nip roll located between the rotary punch rollor rolls and the forward tension roll so as to engage against the formedstrip on the die roll and induce additional friction between the stripand the die roll.
 10. A machine according to claim 7 and including anadditional nip roll located between the rotary punch roll or rolls andthe back tension roll so as to engage against the formed strip on thedie roll and induce additional friction between the strip and the dieroll.
 11. A machine according to claim 7, including additional nip rollslocated between the rotary punch roll or rolls and the forward and backtension rolls so as to engage against the formed strip on the die rolland induce additional friction between the strip and the die roll.
 12. Amethod of continuously forming transverse ribs in metal strip comprisingthe steps of feeding the strip through a transverse rib forming machine,applying tension to the strip over a die roll in the machine by applyinga controlled speed differential between input and output rolls of themachine, and rotary punch forming ribs in the strip at a region of saidapplied tension by a plurality of punch rolls arranged in formingengagement with and around a peripheral section of the die roll andsynchronized for rotation with said die roll.